Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.

An Allen wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example.

Insert plunger into tensioner body by pressing the slack guide.

Keep the slack guide pressed and hold it by pushing the stopper pin through the lever hole and body hole.

Remove the mounting bolts and remove the timing chain tensioner.

Remove timing chain (primary) and crankshaft sprocket.

NOTE

After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the piston heads.

Attach a suitable stopper pin to the right and left camshaft chain tensioners (for secondary timing chains).

Remove intake and exhaust camshaft sprocket bolts. Apply paint to timing chain and camshaft sprockets for alignment during installation. Secure the hexagonal portion of the camshaft using a wrench to loosen the mounting bolts.

Apply liquid gasket to rear timing chain case back side as shown. Use RTV silicone sealant or equivalent.

Align the rear timing chain case and water pump assembly with the dowel pins (right and left) on the cylinder block and install the case. Make sure the O-rings stay in place during installation to cylinder block and cylinder head.

Tighten the mounting bolts in the numerical order as shown. There are two bolt lengths used.

Position the crankshaft so No. 1 piston is set at TDC on the compression stroke. Make sure that the dowel pin hole, dowel pin and crankshaft key are located as shown.

NOTE

Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify.

Install the timing chains (secondary) and camshaft sprockets.

Fig. Secondary timing chain alignment

Fig. Primary timing chain alignment

Fig. Sealer application on front case

Fig. Front timing case bolt torque sequence

Install secondary timing chains and camshaft sprockets. Align the mating marks on the secondary timing chain (gold link) with the ones on the intake and exhaust sprockets (stamped), and install them.

NOTE

Mating marks for the intake sprocket are on the back side of the secondary camshaft sprocket. There are two types of mating marks, circle and oval types. They should be used for the right and left banks, respectively.

Align the dowel pin and pin hole on the camshaft with the groove and dowel pin on the sprocket, and install them.

On the intake side, align the pin hole on the small diameter side of the camshaft front end with the dowel pin on the back side of the camshaft sprocket, and install them.

On the exhaust side, align the dowel pin on the camshaft front end with the pin groove on the camshaft sprocket, and install them.

Mounting bolts for the camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of the dowel pins.

It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the top of sprocket teeth and its extended line in advance with paint.

After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts. Secure the camshaft using a wrench at the hexagonal portion to tighten the mounting bolts.

Pull the stopper pins out from the secondary timing chain tensioners.

Install the primary timing chain as follows:

Install the crankshaft sprocket. Make sure the mating marks on the crankshaft sprocket face the front of the engine.

Install the primary timing chain. Install primary timing chain so the mating mark (punched) on camshaft sprocket is aligned with the yellow link on the timing chain, while the mating mark (notched) on the crankshaft sprocket is aligned with the orange one on the timing chain, as shown.

When it is difficult to align mating marks of the primary timing chain with each sprocket, gradually turn the camshaft using a wrench on the hexagonal portion to align it with the mating marks.

During alignment, be careful to prevent dislocation of mating mark alignments of the secondary timing chains.

Install the internal chain guide and tension guide.

Install slack guide. Do not over tighten the slack guide mounting bolts. It is normal for a gap to exist under the bolt seats when the mounting bolts are tightened to specification.

Install chain tensioner for slack guide. When installing the chain tensioner, push in the sleeve and keep it pressed in with the stopper pin. Remove any dirt and foreign materials completely from the back and the mounting surfaces of the chain tensioner. After installation, pull out the stopper pin by pressing the slack guide.

Reconfirm that the mating marks on the sprockets and the timing chain have not slipped out of alignment.

Install new O-rings on the rear timing chain case.

Install the front oil seal on the front timing chain case. Apply new engine oil to the oil seal edges. Install it so that each seal lip is oriented as shown in illustration. Using a suitable drift, press-fit oil seal until it becomes flush with timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted.

After tightening, retighten them to specified torque in numerical order shown in illustration.

After tightening, retighten them to specified torque in numerical order shown in illustration.

After installing the front timing chain case, check the surface height difference between the following parts on the oil pan mounting surface. If not within specification, repeat the installation procedure.

Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.

For the following operations, perform steps in the reverse order of removal.

NOTE

If hydraulic pressure inside chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is not unusual. Noise will stop after hydraulic pressure rises.